Additive Industries updates MetalFab build processing software

Key Takeaways

• Additive Industries and Materialise have launched the Next‑Generation Build Processor (NGBP) for MetalFab systems.
• NGBP cuts build‑preprocessing time from 46 min to 6 min (≈ 87 % reduction) compared with the Classic Build Processor 2.6.
• The new software adds laser‑load balancing, variable beam‑diameter control, ghost‑vector thermal management, and expanded scan‑strategy options.
• Seamless integration with Materialise Magics lets users import legacy profiles and submit jobs from a single environment.
• Designed for high‑volume, industrial metal AM, NGBP supports the latest MetalFab 420K hardware features and delivers repeatable, production‑grade results.

Overview of the Next‑Generation Build Processor

Additive Industries, in partnership with software specialist Materialise, has released an upgraded build‑processing suite for its MetalFab line of metal‑laser powder‑bed fusion machines. The Next‑Generation Build Processor (NGBP) consolidates the core functions of the previous Build Processor while introducing a suite of new tools aimed at larger, more intricate parts and tighter process control.

Core Improvements

The dramatic speed gain stems from a multiprocessing architecture and refined slicing algorithms that better exploit the MetalFab 420K’s 1 kW laser and 420 kW‑class optics.

New Capabilities Tailored for Industrial Production

Laser Load Balancing & Variable Beam Diameter

NGBP leverages the MetalFab 420K’s ability to distribute laser power across multiple vectors, ensuring uniform energy delivery even in densely packed regions. Operators can now select vector‑type‑dependent beam diameters (e.g., 50 µm for fine features, 150 µm for bulk fills), optimizing melt pool stability and reducing post‑process support.

Ghost‑Vector Thermal Management

A novel ghost‑vector system injects low‑energy laser passes around critical zones, dissipating excess heat and mitigating residual stress. Early field data shows a 12 % reduction in part warpage for high‑thermal‑gradient builds such as aerospace brackets.

Expanded Exposure Strategies

Beyond the standard raster and contour scans, NGBP introduces adaptive exposure where laser power and scan speed are modulated in real time based on in‑process melt‑pool feedback. This capability improves surface roughness (Ra < 8 µm) and density (> 99.9 %) for demanding alloys like Inconel 718 and Ti‑6Al‑4V.

Workflow Integration with Materialise Magics

NGBP is embedded directly into the Materialise Magics environment, allowing users to:

1. Import CAD geometry and apply automated support generation.
2. Select from pre‑configured process profiles or import legacy settings from the Classic processor.
3. Execute a single‑click job submission to the MetalFab machine, with real‑time status updates.

This tight coupling reduces data‑hand‑off errors and shortens the overall production cycle.

Availability and Target Audience

The software is now commercially available to all MetalFab customers, including those operating the newly released MetalFab 420K. It is positioned for manufacturers that demand:

• High‑throughput batch production (≥ 50 parts per shift).
• Consistent mechanical properties across builds.
• Minimal post‑processing due to superior surface finish and dimensional accuracy.

For detailed specifications, licensing options, and support resources, visit the official portal at additiveindustries.com.

Bottom Line

Additive Industries’ collaboration with Materialise has produced a significant leap forward in metal‑additive manufacturing software. By slashing preprocessing time from 46 minutes to just 6 minutes and adding sophisticated laser‑control and thermal‑management tools, the Next‑Generation Build Processor equips industrial users with the speed, precision, and reliability required for large‑scale production. Its seamless integration with Materialise Magics further streamlines the digital workflow, making it a compelling upgrade for any MetalFab‑based operation.